Uniformly-colored, cheese flavored, microwaveable popcorn

ABSTRACT

Corn kernels packaged within a bag can be popped within a microwave oven and then flavored with powdered cheese in two ways. In the first embodiment, the cheese powder is imcorporated in the bag with the corn kernels, oil or shortening, and other ingredient to be subjected to microwave. In the second embodiment, the powdered cheese is applied by sprinkling it on the ingredients within the bag after microwave corn popping, closing the bag, shaking it, and repeating the process several times. In both of these embodiments, when the cheese contacts the hot popcorn, it melts and adheres to the surface of the popcorn. To prevent the melted cheese from giving the popped corn a mottled appearance, a coloring material which generally corresponds to the color of the cheese powder is included as an ingredient in the bag of upoppped kernels. During microwave popping, the coloring is distributed in the bag and coats the popped corn. As a result, a cheese-flavored popcorn with a uniform, pleasing appearance is produced.

BACKGROUND OF THE INVENTION

For many years, people have enjoyed popped kernels of corn as a snackfood. Such snacks are traditionally prepared by either pouring kernelsof corn into a screen-like container suspended over an open fire, byplacing kernels in a covered pan positioned on an operating kitchenstove burner, or by placing kernels in an enclosure having electricalresistance heating elements and passing current through the electricalresistance heating elements. With any of these techniques, the kernelsare heated until they pop. Although these ways of popping corn havingbeen widely used, a more convenient and faster method of preparingpopcorn has long been sought. In addition, it has been desired to popcorn in a container which need not be cleaned but can instead be thrownaway after use.

The demand for fast and convenient preparation of foods has not,however, been limited to popcorn; consumers have also sought to cook awide variety of foods quickly and conveniently As a result of this need,the popularity of microwave ovens for food preparation has increaseddramatically.

As those skilled in microwave technology have known for some time,microwaves heat materials selectively. Those materials that absorbmicrowaves (i.e. lossy materials) are heated by microwaves, whilematerials which reflect microwaves or are transparent to them are notgreatly heated. Many foods are very effectively heated by microwaves,because the foods contain moisture which is very lossy. Consequently,microwaves are absorbed by moisture within the foods which causes thefoods to be rapidly heated. This understanding of the technical basisfor microwave heating has found application in preparing popcorn.Specifically, it has been discovered that moisture within the kernels ofcorn can be heated as they absorb microwaves. As the moisture within thekernels is heated, it vaporizes and eventually causes the kernels topop.

The manufacturers of microwave ovens or microwave ovenware have soughtto capitalize upon the ability of microwave ovens to pop corn byproducing plastic, glass, or ceramic appliances for popping corn. U.S.Pat. No. 4,156,806 to Teich et. al. and U.S. Pat. No. 4,158,760 to Bowenet. al. are representative of such devices. Although such durableappliances have found utility in preparing popcorn with microwaves, theyare relatively expensive and, therefore, cannot be thrown away afteruse. Instead, such appliances must be cleaned for reuse.

An alternative to durable appliances are cardboard containers such asthose disclosed in U.S. Pat. No. 4,036,423 to Gordon and U.S. Pat. No.4,277,506 to Austin. Similar containers can also be manufactured fromplastic, as disclosed in Japanese Pat. No. 60-234562. Although suchcontainers are disposable, their cost of materials and manufacturing arestill relatively expensive. In addition, such containers tend to bebulky and, therefore, difficult to store compactly.

Bags are another way to package microwaveable popcorn. U.S. Pat. No.3,582,363 to Jones discloses the use of a cellophane bag for packagingmicrowaveable popcorn. However, paper bags are more routinely used withU.S. Pat. No. 3,973,045 to Brandenberg et. al., U.S. Pat. Nos. 4,461,031and 4,493,685 both to Blamer, and U.S. Pat. Nos. 4,450,180 and 4,548,826to Watkins being representative of such products.

Conventionally, corn kernels packaged in bags for popping in a microwaveoven require a seal at at least one end of the bag after the bag isfilled with corn kernels, oil or shortening, and optionally salt and/orcoloring. Sealing is usually achieved by providing a layer of adhesivematerial on the inside surface of the bag at the end to be sealed. Theadhesive material is caused to adhere to itself by subjecting it to heatand pressure.

As an alternative to natural flavored microwave popcorn, it has beensuggested that the popcorn be provided with flavorings such as butter,cheese, and caramel. Generally, such flavoring has been effected in oneof three ways--i.e. treating unpopped corn kernels with flavoring,flavoring popcorn as it pops in a microwave oven, and flavoring afterthe corn kernels are popped.

U.S. Pat. No. 4,640,842 to May discloses infusing corn kernels withflavoring (e.g. butter or cheese) by contacting the kernels prior tomicrowave popping with a flavorant dissolved in an aqueous liquid Suchpretreatment, however, increases processing costs, making this flavoringtechnique too expensive.

Flavoring during microwave corn popping is accomplished in a number ofways.

Butter can be applied to popcorn by providing plastic, glass, or ceramicappliances with an attachment to melt butter and allow it to drip on thecorn kernels during microwave popping. Such devices are disclosed byU.S. Pat. No. 4,166,208 to Martel, U.S. Pat. No. 4,496,816 to McNamara,and U.S. Pat. No. 4,563,561 to Vaeth et. al.

U.S. Pat. No. 4,596,713 to Burdette flavors popcorn with butter orcheese by providing a flavorant packet inside the bag used to pop thecorn and positioned above the popping corn. The packet has vent holescovered with a heat softenable film which softens during microwavepopping to disperse the flavoring on the popcorn.

The easiest approach to flavoring microwave popcorn while it is beingpopped is to incorporate flavoring in the bag containing the corn, fat,and other ingredients.

In U.S. Pat. No. 3,851,574 to Katz, savory coatings (e.g. caramel,powdered cheese, or pizza flavorings) are applied to popcorn as it popsin a microwave oven by mixing the kernels in a bag with a hydrophillicor thermoplastic film former, fat, and salt or flavoring. Thehydrophyllic film former may include hydrolysates of corn starch,molasses, or other amorphous sugars or other carbohydrates or gums whichare converted to a film upon exposure to moisture.

Cheese flavorings have also been applied after microwave corn poppinghas ended.

In a commercial operation, U.S. Pat. No. 3,882,255 to Gorham et al.flavors popcorn produced with microwaves by conveying it through aflavoring head where flavorant is sprayed on the popcorn.

For consumers, bags of microwave popcorn have been marketed with aseparate, small packet of cheese powder which is applied to the cornafter popping. Such application is effected by sprinkling some of thepacket's cheese on the popcorn (while hot) through an open end of thebag, closing the bag, and shaking it. This process is repeated severaltimes. As the cheese particles contact the hot popcorn kernels coatedwith oil, they melt and adhere to the surface of the popcorn.

SUMMARY OF THE INVENTION

By conducting consumer preference studies, it has been found thatpopcorn with a uniform, deep yellow color is more appealing andsuggestive of cheese flavoring than uncolored (i.e. natural) popcorn orpopcorn covered only with a pale yellow color. When cheese powder with adeep yellow color is incorporated either in the bag of popcorningredients to be popped with microwaves or in a flavoring packet to besprinkled on the corn after popping, it is not possible to distributethe cheese powder evenly over the popped corn. Consequently, rather thanproducing popcorn with a uniform, deep yellow color, the cheese-flavoredpopcorn has an unappetizing, mottled appearance where the particles ofcheese powder have melted on the lighter colored popcorn.

It has been discovered that a uniform, appetizing appearance can beimparted to popcorn flavored with cheese either during or aftermicrowave popping by utilizing coloring corresponding generally to thatof the cheese. The coloring is included with the other ingredients inthe microwave popcorn bag and is distributed in the bag during poppingto coat the popped kernels. The coloring masks the points where thesimilarly-colored cheese particles melt on the popped corn kernelsregardless of whether the cheese is applied during or after microwavepopping.

The present invention utilizes a bag with gussetted side panels whichare substantially equal to one another as well as front and back panelswhich are substantially equal. The corn kernels, oil or shortening,coloring, etc. fill the bag cross sectionally.

Prior to filling the bags with corn kernels suitable for popping withmicrowaves and then sealing the bags, the bags are formed in accordancewith conventional procedures.

First, separate webs of paper for the outer layer of the bag,greaseproof paper for the inner layer of the bag, and a susceptor suchas a polyester film (e.g. polyethylene teraphthalate) which wasinitially completely metallized and then selectively demetallized areproduced. Such metallized films are disclosed by U.S. Pat. No. 4,267,420to Brastad, U.S. Pat. No. 4,258,086 to Beall, and U.S. Pat. No.4,592,914 to Kuchenbecker. Demetallizing polyester films is also wellknown. Typically, the polyester film is metallized and demetallized sothat the percentage of light transmission of the metallized film is35-75%, preferably 50-65%. The three webs of material are then joinedtogether by conventional techniques to produce a laminate having twolayers (i.e. paper and greaseproof paper) in some locations and threelayers (i.e. paper, metallized polyester film, and greaseproof paper) inother locations. The laminate web is then folded and sealed along thelength of the web to produce a tubular web which can then be cut intotubular sections of smaller length.

One end of each of the tubular segments is then sealed in a conventionalmanner. For example, heat and pressure can be applied to the end of thebag so that an adhesive material coated on the interior of the tube willbond the tube walls together at this location. The sealed end of thetube can then be folded across the bag and against either the front orback panel with an adhesive material being applied to maintain thisfold.

After sealing one end of the bag, kernels of corn and then hot,liquified oil or shortening mixed with salt and coloring can be injectedinto the bag. If a lay-down bag is utilized (see U.S. Pat. No. 4,219,573to Borek), it is preferred to maintain these injected materials at alocation substantially equidistant from the ends of the bag. This isachieved by again folding the sealed end across the front or back panelof the bag at a location substantially equal to about one third of thedistance between the ends of the bag. Alternatively, the bag can befolded closer to or farther from the bottom (i.e. 25% to 40% of thedistance between the ends of the bag). In addition, instead of foldingprior to filling, the bag can be clamped at a location during fillingand folded later. No such folding is required with a stand-up bag (seeU.S. Pat. No. 4,571,337 to Cage et al), because corn kernels and oil orshortening will naturally flow to the bottom panel of the bag which willdesirably rest on the floor of the microwave oven. After theseingredients are injected into the bag, the hot liquified oil orshortening will cool and solidify with the corn kernels and otheringredients.

After filling, the other end of the bag is sealed using heat andpressure applied to this end of the bag so that an adhesive materialcoated on the interior of the bag at this end will bond the interior ofthe bag walls together at this location. After sealing, the top third ofthe bag is folded over the front or back panel so that a compact packageis produced. Again, alternatively, the top end of the bag can be foldedbetween 25% to 40% of the distance between the ends of the bag dependingon how the bottom end is folded. To increase the shelf life of theproduct, it is desirable to enclose the filled and sealed bag in aplastic pouch made from a material conventionally utilized for suchpurposes (e.g. polypropylene film with a heat seal layer coated on orcoextruded on one or two surfaces). Alternatively, the product's shelflife can be enhanced by freezing the packaged product.

In the first embodiment of applying cheese flavoring during microwavecorn popping, powdered cheese is interspersed with the corn, oil orshortening, and other ingredients in the bag to be subjected tomicrowaves. As a result, the cheese powder and coloring are applied tothe corn kernels during popping to produce a cheese-flavored popcornwith a deep colored, uniform, and unmottled appearance.

In the second alternative embodiment, the popcorn is flavored afterpopping by sprinkling powdered cheese into the popcorn bag aftermicrowave popping. The cheese is packaged in an open-ended packet formedfrom a laminate of paper, polymeric material and/or metal foil.Preferably, the packet is made from a laminate having an inner layer ofa polyethylene/ionomer coextrusion surrounded by aluminum foil which iscovered by a layer of polyethylene over which is a sheet of paper. Thepacket is formed by heat sealing two sheets of the laminate along theiredges.

For the first embodiment of the present invention where cheese flavoringis incorporated in the microwave popcorn bag with the other ingredients,the mass of ingredients in the bag totals 0.0973 to 0.1013 kilograms(preferably 0.0993 kilograms) and includes:

    ______________________________________                                        Popcorn kernels (yellow,                                                                             50-56 wt %                                             shelled medium kernels of                                                                            (preferably                                            high quality, sized so that                                                                          53.53 wt %)                                            60 to 75 kernels will have                                                    a total mass of l0 grams)                                                     Oil (partially         32-38 wt %                                             hydrogenated mixture   (preferably                                            of 90 wt % soybean oil and                                                                           35.37 wt %)                                            10 wt % cottonseed oil)                                                       Salt (average size     1.4-2.0 wt %                                           30-65 microns)         (preferably                                                                   1.70 wt %)                                             Coloring (yellow food  .60-.67 wt %                                           dyes)                  (preferably                                                                   .64 wt %)                                              Cheese powder (containing                                                                            7.0-9.2 wt. %                                          dried cheese, salt, whey,                                                                            (preferably                                            delactosed whey, sour cream,                                                                         8.81 wt %).                                            flavor, color, spices, etc.                                                   ______________________________________                                    

In this embodiment, the cheese powder can be any commercially availablecheese powder formulation suitable for use in microwave ovens. Suchproducts are sold by Food Materials Corporation and Universal FoodsCompany.

In the second embodiment of the present invention, where the cheeseflavoring is in a packet separate from the bag of microwave popcorningredients, the mass of the ingredients in the microwave popcorn bagtotals 0.0878 to 0.0918 kilograms (preferably 0.0898 kilograms) andincludes:

    ______________________________________                                        Popcorn kernels (yellow,                                                                            60-70 wt %                                              shelled medium kernels of                                                                           (preferably                                             high quality, sized so that                                                                         68.07 wt %)                                             60 to 75 kernels will have                                                    a total mass of l0 grams)                                                     Oil (partially        25-30 wt %                                              hydrogenated mixture  (preferably                                             of 90 wt % soybean oil and                                                                          29.95 wt %)                                             10 wt % cottonseed oil)                                                       Salt (average size    1.0-2.5 wt %                                            30-65 microns)        (preferably                                                                   1.41 wt %)                                              Coloring (yellow food 0.54-0.60 wt %                                          dyes)                 (preferably                                                                   0.57 wt %).                                             ______________________________________                                    

The packet includes 0.196-0.28 grams of cheese powder per gram ofpopcorn kernels in the bag (preferably 0.25 grams of cheese powder pergram of popcorn kernels in the bag) of cheese powder.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the back panel of an unfilled, lay-downbag made in accordance with the present invention;

FIG. 2 is a perspective view of the front of an unfilled lay-down bagmade in accordance with the present invention and with one layer of thefront panel of the bag being cut away;

FIG. 3 is a cross-sectional side view of a lay-down bag in accordancewith the present invention with one end sealed and filled with cornkernels and oil or shortening;

FIG. 4 is a top cross-sectional view taken along line 4--4 of FIG. 3;

FIG. 5 is a perspective view of a kit for preparing microwaveablepopcorn and flavoring it with cheese, according to the second embodimentof the present invention, which includes kernels of corn and shorteningor oil and having both ends sealed and a packet of powdered cheese.

FIG. 6 is a perspective view of a lay-down bag made in accordance withthe present invention containing kernels of corn and oil or shorteningwith the bag having both ends sealed and being positioned within amicrowave oven;

FIG. 7 is a perspective view of a lay-down bag made in accordance withthe present invention containing kernels popped with microwaves;

FIG. 8 is a perspective view showing cheese from the packet being addedto the bag, according to the second embodiment of the present invention.

FIG. 9 is a perspective view showing the bag being shaken to distributethe previously-added cheese over the popped corn kernels, according tothe second embodiment of the present invention.

FIG. 10 shows a perspective view of a stand-up bag filled with cornkernels and oil or shortening and having a sealed end;

FIG. 11 is a side cross-sectional view of a stand-up bag in asemi-compacted position, filled with unpopped corn kernels and oil orshortening, and sealed in accordance with the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

Before describing the present invention with respect to the drawings, itshould be understood that FIGS. 1-4, 6-7, and 10-11 are applicable bothto the first embodiment of the present invention, where cheese powder isincorporated in the microwave popcorn bag with the corn kernels, oil orshortening, and other ingredients to be subjected to microwaves, and tothe second embodiment of the present invention, where cheese powder isadded to the microwave popcorn bag after the corn kernels are popped.FIGS. 1-2 just show the microwave popcorn bag without its ingredientswhich is the same for both embodiments. As to FIGS. 3-4, 6-7, and 10-11which show the microwave popcorn bag with its popped or unpoppedcontents, the only difference between the embodiments (i.e. the presenceor absence of cheese in the microwave bag) would not be apparent fromthese drawings. FIG. 5, showing the microwave popcorn bag with unpoppedingredients and the cheese flavor packet, relates to the secondembodiment where cheese from the packet is sprinkled into the bag aftercorn popping; however, the bag and its ingredients shown in this Figurewould be the same for the first embodiment except that it would alsocontain cheese powder. FIGS. 8-9 relate solely to the second embodiment.

FIG. 1 is a perspective view of the back of an empty, lay-down bag 10.The bag is provided with a front panel 16, a back panel 18, and a pairof inwardly-folded, gussetted side panels 20 all of which extend betweenan open top end 12 and a sealed bottom end 14. Bottom end 14 is foldedover and bonded to back panel 18 at bottom seal 22. Bag 10 is sealedlongitudinally by back panel seal 28 which extends between top end 12and bottom end 14. The gussetted side panels 20 extend inwardly towardeach other between front panel 16 and back panel 18; however, a centerstrip 24 of front panel 16 and back panel 18 lies between the innermostpoint of the gussetted side panels 20. The interior of bag 10 near topend 12 is provided with an adhesive 26 which bonds to itself uponapplication of heat and pressure.

FIG. 2 is a perspective view of the front of an empty, lay-down bagaccording to the present invention. Within front panel 16 is a susceptor30 formed from a metallized and selectively demetallized polyester film.Although a wide variety of metals and polyester films can be used toproduce susceptor 30, the preferred polyester film is polyethyleneterephthalate, while the metal is preferably aluminum. Instead ofmetallizing and demetallizing polyester film, a metallized polyesterfilm can be cut to the desired size and placed between layers of paperor other laminating materials. Alternatively, a susceptor material canbe printed on a paper layer or on another laminating material.

Front panel 16 and back panel 18 have a width across top end 12 which isgenerally about 1.3 to 1.5 and preferably about 1.4 times as large asthe width of each of the gussetted side panels 20 folded into bag 10.The ratio of the width of susceptor 30 across bag 10 to its lengthextending partially between top end 12 and bottom end 14 is generallyabout 1:1.0 to 1:1.4, preferably about 1:1.15.

FIG. 3 is a side cross-sectional view of a lay-down bag according to thepresent invention which is filled with unpopped corn kernels 32 andshortening or oil 34. These materials and optionally coloringadditive(s) or salt are injected through top end 12 of bag 10, asindicated by arrow A. Preferably, the kernels are first injected, withthe shortening or oil mixed with salt and coloring being addedsubsequently. Prior to injecting corn kernels 32 and oil or shortening34, the lower third of the bag is folded toward back panel 18 to form afolded lower end 36. As a result, the unpopped kernels of corn 32, theshortening or oil 34, and any other ingredients are held within themiddle third of the lay-down bag substantially equidistant from ends 12and 14. Although the shortening or oil 34 is added in a hot liquifiedstate, it eventually cools and solidifies in admixture with the otheringredients.

FIG. 3 also shows a side cross-sectional view of the laminates whichform bag 10, while FIG. 4 shows a top cross sectional view of the bagshown in FIG. 3 taken along line 4--4. Bag 10 is formed from a threelayered laminate at front panel 16 and a two layered laminate everywhere else except at back panel seal 28 where the two layered laminatesoverlap. The three layered laminate at front panel 16 consists of anouter paper layer 40, and an inner greaseproof paper layer 42, and asusceptor 30 between layers 40 and 42. Elsewhere, the bag is onlylaminated by outer paper layer 40 and inner greaseproof paper layer 42.

As they relate to the two embodiments of the present invention, FIGS. 3and 4 would be the same except that in the first embodiment (but not thesecond embodiment) the microwave popcorn bag would contain cheese powderinterspersed with and in addition to the depicted corn kernels, oil orshortening, coloring, etc. For the second embodiment where cheese powderis added to the bag after microwave corn popping, the microwave popcornbag contains corn kernels, oil or shortening, color, etc., while thecheese powder is in a separate packet, as described in FIG. 5.

FIG. 5 shows a perspective view of a lay-down bag filled with unpoppedkernels of corn 32 and solidified oil or shortening 34 and having topend 12 and bottom end 14 sealed. This filled and sealed bag not only hasa folded lower end 36, it is also provided with an upper end 38 foldedtoward back panel 18. Folded lower end 36 and folded upper end 38 can befolded over the portion of bag 10 containing unpopped corn kernels 32and oil or shortening 34 for compact packaging and shipping. In thisfolded position, the bag can be frozen and/or sealed within a pouch (notshown) of plastic (e.g. polypropylene film) to increase the shelf lifeof the product.

Bag 10 is sealed across top end 12 by a plurality of sealing lines 44which are impressed into the exterior of the bag by a pair of sealingjaws (not shown) at least one of which is heated. When pressure withinbag 10 exceeds a certain level due to the generation of water vapor fromthe popping corn kernels, the seal formed by sealing lines 44 weakens,and bag 10 opens at top end 12.

FIG. 5 also shows a perspective view of a packet 46 of powdered cheese48. Packet 46 is flexible and preferably made from a laminate comprisingan inner layer of a polyethylene/ionomer coextrusion surrounded byaluminum foil which is covered by a layer of polyethylene over which isa sheet of paper. The cheese powder 48 includes: spray dried cheese,artificial and natural flavoring, coloring, and spices. The coloring inboth the cheese powder in packet 46 and in the oil or shortening in bag10 is the same--preferably a blend of FD&C Yellow Nos. 5 and 6.

For the first embodiment of the present invention, the microwave popcornbag would be the same as bag 10 in FIG. 5, except that the cheese powderwould be in the bag rather than in a separate packet. Again, the cheesepowder and the oil or shortening would have the same color--preferably ablend of FD&C Yellow Nos. 5 and 6. The same is true for FIG. 6.

As shown in FIG. 6, the sealed bag filled with corn kernels, solidifiedshortening or oil, etc. is placed on the floor 52 of microwave oven 50.The bag is positioned with front panel 16 which contains susceptor 30closest to the oven floor 52. In addition, folded lower end 36 andfolded upper end 38 are spread apart from the portion of the bagcontaining corn kernels 32 and solidified shortening or oil 34. Afterplacing the bag on oven floor 52 in this manner, the door (not shown) ofmicrowave oven 50 is closed, and the microwave oven is turned on forapproximately 5 minutes. The kernels then begin to pop as a result ofmoisture within each kernel vaporizing. This evaporation of moisturecauses the bag to expand such that back panel 18 moves upwardly awayfrom front panel 16. In addition, inwardly-folded gussetted side panels20 move outwardly so that each of the folded parts comprising eachgusset move apart.

Instead of placing the bag on the actual floor of the oven 52, it canrest on an elevated support provided as an accessory to the oven or asan element of the packaging.

FIG. 7 is a perspective view of a sealed lay-down bag containing poppedcorn 54. As a result of vaporized moisture produced when corn kernelsare popped, the bag has expanded. During popping of the corn kernels,the evolved water vapor has increased the pressure within the bag abovea predetermined pressure at which the seal formed by sealing lines 44will open. Once this seal opens, vapors V are vented from the bag.

By utilizing the package of the present invention, a large percentage ofthe kernels in the package pop; however, a few unpopped corn kernels 32will remain after popping. Once popping has begun, the popped kernels 54tend to collect within the bag at a level above the unpopped cornkernels 32. As shown in FIG. 7, these unpopped kernels 32 form a layerat the bottom of the bag adjacent to susceptor 30. By being in alocation adjacent the susceptor, the likelihood that the unpoppedkernels will be popped increases, because heat emanates from thesusceptor as a result of it being in contact with microwaves. Afterpopping, bag 10 can be opened for either consumption if the firstembodiment of the invention is practiced or addition of cheese flavoringaccording to the second embodiment of the invention.

As it relates to the two embodiments of the present invention, FIG. 7 isthe same except that in the first embodiment (but not the second), thepopped corn has a coating of cheese and coloring corresponding to thecolor of the cheese. By contrast, in the second embodiment, the popcornwould not be coated with cheese but only with coloring corresponding tothat of the subsequently-added cheese, as described below with referenceto FIGS. 8-9.

FIGS. 8-9 are perspective views showing how cheese powder 48 is added tobag 10 containing popped corn, according to the second embodiment of thepresent invention. The user does this by grasping packet 46 with onehand H1 and by holding bag 10 with his other hand H2. Cheese powder 48is then poured from a previously-opened end of packet 46 into bag 10through opened top end 12. After cheese powder is added in this manner,the cheese is distributed over the popped corn kernels in bag 10 byholding top end 12 closed with hands H1 and H2 and shaking the bag.Preferably, cheese powder 48 is applied to the corn kernels by adding aportion of the powder in packet 46 to bag 10, shaking the bag, andrepeating these steps two more times. As a result, the present inventionproduces a cheese-flavored popcorn with a uniform, unmottled, andpleasing appearance.

FIGS. 10 and 11 show another embodiment of the present invention whichutilizes a stand-up bag 110. This bag is provided with a front panel116, a back panel 118, and a pair of inwardly-folded gussetted sidepanels 120 which extend between a top end 112 and conventional bottompanel 114. As in the lay-down bag embodiment, a center strip 124 isformed between the innermost extent of the inwardly-folded gussettedside panels 120. Susceptor 130, a metallized polyester film, is locatedin bottom panel 114. The laminations of the stand up bag embodiment aresimilar to those of the lay-down bag embodiment, except that thestand-up bag embodiment has the three layer lamination (i.e. outer paperlayer 140, inner greaseproof paper layer 142, and susceptor ofmetallized polyethylene terephthalate 130) formed in bottom panel 114instead of the front panel. Front panel 116, back panel 118, andinwardly-folded gussetted side panels 120 all are formed from a laminateof two layers--i.e. an outer paper layer 140 and an inner greaseproofpaper layer 142.

Like the lay-down bag embodiment, the stand-up bag embodiment also has alongitudinally-extending back seam (not shown) on back panel 118. Inaddition, the interior of the bag adjacent top end 112 is provided witha layer of adhesive (not shown) which will seal the bag at top end 112upon the application of pressure and heat from a pair of sealing jaws.

The packaged product shown in FIGS. 10 and 11 is prepared by firstfilling stand-up bag 110 with unpopped kernels 132, then filling withoil or shortening, a coloring additive, and, optionally, salt 134, andfinally sealing top end 112. As shown by the arrows in FIG. 11, stand-upbag 110 can be folded into thirds for compact packaging, storage, andshipment by moving back panel 118 downwardly toward bottom panel 114 andthen folding upper end 138 against the opposite side of bottom panel114.

Following filling and sealing of stand-up bag 110, the oil or shortening134 cools and solidifies. When the filled and sealed stand-up bag 110 isplaced in a microwave oven so that bottom panel 114 rests on the ovenfloor 152 and the oven is turned on, moisture within the kernels beginsto vaporize which eventually pops the kernels. As the kernels pop, theywill move upwardly within the bag. The unpopped kernels will tend toreturn to a position closer to bottom panel 114 than the popped kernelsdue to their difference in density. This brings the unpopped kernelscloser to susceptor 130 so that heat emanating from the susceptor canmore easily pop the kernels. The generation of water vapor withinstand-up bag 110 as a result of kernels being popped causes the bag toexpand at front panel 116, back panel 118, and inwardly-folded gussettedside panels 120. The top end 112 of stand up bag 110 is sealed in thesame manner as the top end of the lay-down bag. Specifically, aplurality of impressed sealing lines 144 extend across top end 112 toseal the bag until a predetermined pressure is reached.

As they relate to the two embodiments of the present invention, FIGS.10-11 would be the same except that in the first embodiment (but not inthe second embodiment), cheese flavoring would be interspersed with thecorn, oil or shortening, coloring, etc. in bag 110. In the secondembodiment, the cheese would be stored in and applied from a separatepouch like that shown in FIGS. 5 and 8-9.

EXAMPLE 1

To a gussetted paper bag constructed as described above with regard toFIGS. 1-9, 53.2 grams of medium yellow hybrid popcorn, 35.1 grams ofmelted partially hydrogenated soybean oil mixed with 1.7 grams ofsuperfine salt, 0.64 grams of a color blend of FD&C Yellow Nos. 5 and 6dispersed in oil, and 8.8 grams of cheese powder formed from a mixtureof cheddar cheese, powder, salt, whey, sour cream, corn starch, naturaland artificial flavors, coconut oil, reduced lactose whey, MSG, citricacid, lactic acid, the color blend of FD&C Yellow Nos. 5 and 6, andspice are added. The bag is heat sealed at the open end, folded intothirds, and held at room temperature for 24 hours to allow the oil tosolidify.

The heat sealed bag is placed in a microwave oven with susceptor sidedown. The popcorn is heated for 3 to 31/2 minutes on high until poppingis completed. The bag, with a popped corn volume of 2200 cc and 3.7-8.0%of unpopped kernels, is removed from the microwave oven and allowed tocool with the top open.

The resulting product has a deep, attractive yellow/orangish color,evenly spread over most of the kernels of popped corn and has a pleasantcheddar cheese flavor when eaten.

EXAMPLE 2

A bag of microwaveable popcorn is manufactured and popped as in Example1 above, except that the 8.8 grams of cheese powder is replaced with 8.4grams of nacho-flavored cheese powder. The nacho-flavored cheese powderis like the cheddar cheese flavored powder in Example 1, except that thenacho cheese flavor additionally includes romano and parmesan cheesesand onion and garlic spices.

The heat sealed bag containing the unpopped corn is placed in amicrowave oven, susceptor side down. The popcorn is heated for 3 to 31/2minutes until most of the corn kernels are popped. The resulting popcornwill have a deep yellow color with a pleasant nacho cheese flavor.

EXAMPLE 3

To a gussetted paper bag constructed as described with respect to FIGS.1-9 above, 61 grams of medium yellow hybrid popcorn, 27 grams of meltedpartially hydrogenated soybean oil mixed with 1.3 grams of superfinegranulated salt and 0.5 grams of a color blend of FD&C Yellow #5 and #6dispersed in oil are added. The bag is heat sealed at the open end,folded into thirds and held at room temperature for 24 hours to allowthe oil to solidify.

To a separate 4 inch by 5 inch pouch made from a laminate of an outerlayer of aluminum foil and an inner layer of polymeric material, 15grams of a dried cheddar cheese flavored powder containing cheddarcheese, salt, whey, sour cream, corn starch, natural and artificialflavors, coconut oil, reduced lactose whey, MSG, citric acid, lacticacid, the color blend of FD&C Yellow #5 and #6, and spice are added, andthe pouch is sealed.

The heat sealed bag containing the unpopped corn is placed in amicrowave oven with the susceptor side down. The popcorn is heated for 3to 31/2 minutes until popping is completed. The bag, with a popped cornvolume of 2200 cc and 8-10% of unpopped kernels, is removed from themicrowave oven and allowed to cool for 2 to 3 minutes with the top open.

To the opened bag containing the popped corn, about 1/2 of the cheddarcheese flavored powder from the pouch is added. The bag is then closedand vigorously shaken for about 10 to 15 seconds. This procedure isrepeated with the remaining cheese powder.

The resulting product has a deep, attractive yellow/orangish colorevenly distributed over most of the kernels of popped corn and has apleasant cheddar cheese flavor when eaten.

EXAMPLE 4

A bag of microwaveable popcorn is manufactured and popped exactly likethat described in Example 3 above. To a separate small pouch like thatdescribed in Example 3, 15 grams of nacho-flavored cheese powder isadded, and the pouch is heat sealed. The nacho cheese flavor is like thecheddar cheese flavored powder in Example 3, except that the nachocheese flavor additionally includes romano and parmesan cheeses andonion and garlic spices.

The heat sealed bag containing the unpopped corn is placed in amicrowave oven susceptor side down. The popcorn is heated for 3 to 31/2minutes until most of the corn kernels are popped.

The bag containing the popped corn is removed from the oven and emptiedinto a large bowl. The nacho cheese flavored powder is then sprinkledslowly over the popcorn while tossing the corn with a large spoon untilit is evenly coated.

The resulting popcorn from this procedure will be deep yellow in colorwith a pleasant nacho cheddar cheese flavor.

Although the invention has been described in detail for the purpose ofillustration, it is understood that such detail is solely for thatpurpose, and variations can be made therein by those skilled in the artwithout departing from the spirit and scope of the invention which isdefined by the following claims.

We claim:
 1. In a method of preparing popcorn with microwaves and thenimparting a cheese flavoring to the popcorn comprising:subjecting apackage comprising a plurality of corn kernels and oil or shortening tomicrowaves to form popped corn kernels and sprinkling powdered cheese ofdifferent color than said popped corn kernels on the popped corn kernelsonly in an amount at which the popped corn kernels will have a mottledappearance, the improvement comprising: incorporating in the packageprior to popping a food color substantially similar to the color of thecheese flavoring and in an amount such that a cheese-flavored popcornproduct with a uniform, unspeckled, and pleasing appearance is produced.2. A method according to claim 1, wherein the powdered cheese ispackaged in a sealed, flexible packet.
 3. A method according to claim 2,wherein the flexible packet is a laminate having layers of polymericmaterial, metal foil, and paper.
 4. A method according to claim 1,wherein said sprinkling is effected while the popped corn kernels are inthe package and further comprising:shaking the package following saidsprinkling to distribute the powdered cheese on the popped corn kernels.5. A method according to claim 4, further comprising:after said shaking,repeatedly sprinkling powdered cheese on the popped corn kernels whilein the package and shaking the package.
 6. A method according to claim1, wherein the powdered cheese contains food color.
 7. A methodaccording to claim 6, wherein the food color in the powdered cheese andthe package is the same.
 8. A method according to claim 7, wherein thefood color is a blend of FD&C Yellow Nos. 5 and
 6. 9. A method accordingto claim 1, wherein the powdered cheese comprises spray dried cheese,artificial and natural flavoring, food color, and spices.
 10. A methodaccording to claim 1, wherein the package is an elongate bag with a pairof ends between which a front panel, a back panel, and inwardly-folded,gussetted side panels connecting the front panel and the back panelextend.
 11. A method according to claim 10, wherein said sprinkling iseffected while the popped corn kernels are in the bag and furthercomprising:shaking the bag following said sprinkling to distribute thepowdered cheese on the popped corn kernels.
 12. A method according toclaim 11, further comprising:after said shaking, repeatedly sprinklingcheese on the popped corn kernels while in the bag and shaking the bag.13. In a product for preparing cheese-flavored popcorn with microwavescomprising:a package containing a plurality of unpopped corn kernels andeither oil or shortening, wherein said package is suitable for placementin a microwave oven to effect popping of the corn kernels withmicrowaves to form popped corn kernels and a powdered cheese ofdifferent color than said popped corn kernels and present only in anamount at which, when said powdered cheese is applied to said poppedcorn kernels, said popped corn kernels have a mottled appearance,wherein the improvement comprises incorporating in said package a foodcolor substantially similar to the color of said powdered cheese,whereby, during popping of the corn kernels, said food color isdistributed in said package and coats the popped corn so that when saidpowdered cheese is applied to the popcorn, a cheese-flavored popcornproduct with a uniform, unmottled, and pleasing appearance is produced.14. A product according to claim 13, wherein said powdered cheese iscontained separate from said package containing the unpopped cornkernels, the oil or shortening, and the food color.
 15. A productaccording to claim 14, wherein said product is a kit comprising saidpackage and a packet containing said powdered cheese.
 16. A productaccording to claim 15, wherein the packet is a flexible laminate formedfrom layers of polymeric material, metal foil, and paper.
 17. A productaccording to claim 13, wherein said powdered cheese is admixed with theunpopped corn kernels, the oil or shortening, and the food color in saidpackage.
 18. A product according to claim 14 or 17, wherein said packageis an elongate bag with a pair of ends between which a front panel, aback panel, and inwardly-folded, gussetted side panels connecting thefront panel and the back panel extend.
 19. A product according to claim18, wherein the bag is a lay-down bag.
 20. A product according to claim18, wherein the bag is a stand-up bag having a flat bottom panel at oneend.
 21. A product according to claim 18, wherein the bag is a laminatehaving an outer layer of paper, an inner layer of greaseproof paper, anda microwave susceptor between the inner and outer layers in part of thebag.
 22. A product according to claim 18, wherein the bag is a laminatehaving an outer layer of paper, an inner layer of polymeric material,and a microwave susceptor between the inner and outer layers in part ofthe bag.
 23. A product according to claim 18, wherein the plurality ofcorn kernels, the oil or shortening, and the food color substantiallyfill the bag cross-sectionally.
 24. A product according to claim 18,wherein the corn kernels, the oil or shortening, and the food color issubstantially equidistant from the ends of said bag.
 25. A productaccording to claim 13, wherein the oil or shortening is solidified. 26.A product according to claim 13, further comprising salt in admixturewith said corn kernels and said oil or shortening.
 27. A productaccording to claim 13, wherein said powdered cheese further comprisesfood color.
 28. A product according to claim 27, wherein the food colorin said powdered cheese and said package is the same.
 29. A productaccording to claim 28, wherein the food color is a blend of FD&C YellowNos. 5 and
 6. 30. A product according to claim 13, wherein said powderedcheese comprises spray dried cheese, artificial and natural flavoring,food color, and spices.
 31. In a kit for preparing cheese-flavoredpopcorn with microwaves comprising:an elongate bag with a pair of endsbetween which a front panel, a back panel, and inwardly-folded gussettedside panels connecting the front panel and the back panel extendcontaining a plurality of corn kernels and solidified oil or shorteningas ingredients, the ingredients substantially filling said bagcross-sectionally equidistant from the ends of the bag, said bag being alaminate having an outer paper layer, an inner paper layer ofgreaseproof paper, and a microwave susceptor between the inner and outerlayers in the front panel of said bag, said bag being suitable forplacement in a microwave oven to effect popping of the corn kernels withmicrowaves to form popped corn kernels; a sealed, flexible packet formedfrom a laminate having layers of a polymeric material, metal foil, andpaper and containing a powdered cheese formulation comprising a blend ofF D & C Yellow Nos. 5 and 6 food color, the powdered cheese formulationbeing of different color than said popped corn kernels and being presentonly in an amount at which, when said powdered cheese formulation isapplied to the plurality of popped corn kernels, after microwavepopping, said popped corn kernels have a mottled appearance, wherein theimprovement comprises incorporating in said bag a blend of F D & CYellow Nos. 5 and 6 food color substantially similar to the food colorin the powdered cheese formulation and in an amount such that, duringmicrowave popping of the corn kernels, the food color in said bag isdistributed and coats the popped corn so that when the powdered cheeseformulation in said packet is applied to the popcorn in said bag, afterits removal from the microwave oven, a cheese-flavored popcorn productwith a uniform, unmottled, and pleasing appearance is produced.
 32. In aproduct for preparing cheese-flavored popcorn with microwavescomprising:an elongate bag with a pair of ends between which a frontpanel, a back panel, and inwardly-folded gussetted side panelsconnecting the front panel and the back panel extend, said bag being alaminate having an outer paper layer, an inner layer of greaseproofpaper, and a microwave susceptor between the inner and outer layers inthe front panel of said bag, said bag being suitable for placement in amicrowave oven to effect popping of the corn kernels with microwaves toform popped corn kernels and popcorn ingredients substantially fillingsaid elongate bag cross-sectionally equidistant from the ends of thebag, said popcorn ingredients comprising a plurality of corn kernels,solidified oil or shortening, and a powdered cheese formulationcomprising F D & C Yellow Nos. 5 and 6 food color, the powdered cheeseformulation being of different color than said popped corn kernels andbeing present only in an amount at which, when the powdered cheese isapplied to the plurality of popped corn kernels, said popped cornkernels have a mottled appearance, wherein the improvement comprisesincorporating in said bag a blend of F D & C Yellow Nos. 5 and 6 foodcolor substantially similar to the food color in the powdered cheeseformulation, and in an amount such that, during microwave popping of thecorn kernels, the food color in said bag is distributed and coats thepopped corn so that when the powdered cheese formulation is applied tothe popcorn, a cheese-flavored popcorn product with a uniform,unmottled, and pleasing appearance is produced.